3D Numerical Study of External Axial Magnetic Field-Controlled High-Current GMAW Metal Transfer Behavior

Abstract

For gas metal arc welding (GMAW), increasing the welding current is the most effective way to improve welding efficiency. However, much higher current decreases the welding quality as a result of metal rotating-spray transfer phenomena in the high-current GMAW process. In this work, the external axial magnetic field (EAMF) was applied to the high-current GMAW process to control the metal transfer and decrease the welding spatters. A unified arc-droplet coupled model for high-current GMAW using EAMFs was built to investigate the metal rotating-spray transfer behavior. The temperature fields, flow fields in the arc, and droplet were revealed. Considering all the heat transferred to the molten metal, the Joule heat was found to be the dominant factor affecting the droplet temperature rise, followed by the anode heat. The conductive heat from the arc contributed less than half the value of the other two. Considering the EAMFs of different alternating frequencies, the arc constricting effects and controlled metal transfer behaviors are discussed. The calculated results agree well with the experimental high-speed camera observations.

Mechanisms of Gravitational Influence on Weld Pool Behavior and Weld Bead Performance in Variable Polarity Plasma Arc Welding across Different Welding Position

“…Numerous scholars conducted research on VPPA welding in different welding positions. Maintaining the flow behavior of molten metal is considered a key factor in ensuring welding stability [21,22], making the study of molten metal flow within the weld pool crucial [23][24][25]. Wu et al established a multi-factor-coupled model through simulation to investigate the influence of different driving forces on the weld pool flow behavior during keyhole welding [26].…”